Integrated foam/wood ramp system for products with casters

ABSTRACT

A shipping carton with a ramp system which is integrated into the packaging in a unique way which facilitates positioning of the ramp system for use while also facilitating storage of the ramp system during shipment of the product enclosed within the packaging.

FIELD AND BACKGROUND OF INVENTION

[0001] This invention relates to packaging used to ship products and tothe combination of ramps, cushions, and a shipped product.

[0002] A problem is presented when it is necessary to remove a productsuch as a heavy computer system from a shipping pallet without liftingthe system. This problem has been attacked in the past with rampingsystems which usually include a single large wood ramp made out ofplywood. Another common ramp design is to used two solid wood ramps (orother materials such as steel or plastic) for each caster that containbuilt in caster guides to keep the casters from falling off the rampswhen moving the system down the ramps. These methods can be expensiveand drive complexity into the ship package design since the packagingdesigner must find a place to store the ramps in or on the packageduring shipment and a method to secure the ramp when used if the ramp isto be shipped with the product. If the ramp must be secured thenextensive instructions are required that must be followed in order forthe ramp to be used properly.

[0003] Products of the types described are frequently provided withsupporting casters to facilitate movement of the system during use. Suchproducts are here referred to a castered products. Handling casteredproducts in packaging and shipment also requires a separate method tosupport the weight imposed through the casters under any bottom cushionprovided (typically, foam cushioning material) since the load bearingarea of the casters is small. In most cases a packaging designer mustput a dense material under the casters to spread the load bearing weightbetween the casters and the foam cushioning.

SUMMARY OF THE INVENTION

[0004] It is a purpose of this invention to solve the identifiedproblems by providing an easy to use ramping system that is intuitiveand cost effective. This purpose is pursued by providing a ramp systemwhich is integrated into the packaging in a unique way which facilitatespositioning of the ramp system for use while also facilitating storageof the ramp system during shipment of the product enclosed within thepackaging. Use of the ramp system of this invention is intuitive for aperson unpacking a shipped product.

BRIEF DESCRIPTION OF DRAWINGS

[0005] Some of the purposes of the invention having been stated, otherswill appear as the description proceeds, when taken in connection withthe accompanying drawings, in which:

[0006]FIG. 1 is a schematic perspective view of the elements of thisinvention, showing the shipping carton as arranged for packaging of aproduct and with the product and a portion of the packaging explodedupwardly.

[0007]FIG. 2 is a schematic perspective view similar to FIG. 1 andshowing the elements of the present invention as arranged for unloadingof a product and with the product and a portion of the packagingexploded upwardly.

[0008]FIG. 3 is a section view through a portion of the elements shownin FIGS. 1 and 2.

DETAILED DESCRIPTION OF INVENTION

[0009] While the present invention will be described more fullyhereinafter with reference to the accompanying drawings, in which apreferred embodiment of the present invention is shown, it is to beunderstood at the outset of the description which follows that personsof skill in the appropriate arts may modify the invention here describedwhile still achieving the favorable results of the invention.Accordingly, the description which follows is to be understood as beinga broad, teaching disclosure directed to persons of skill in theappropriate arts, and not as limiting upon the present invention.

[0010] The present invention is a packaging configuration which in itssimplest form is a container indicated at 10 in FIG. 1 and having atleast four side walls 11 (two being visible) and a base encircled bysaid side walls and generally indicated at 12. The elements of theinvention are illustrated in FIG. 1 in an exploded view, as if thecontainer is lifted from the base in order to reveal the elements. Itwill be understood that, in shipment, the side walls 11 are secured tothe base 12 to enclose a castered product 13.

[0011] The invention incorporates at least one product unloading rampmember, each having a portion hingedly connected to the base andextending therefrom to lie alongside one of said side walls while saidbase is encircled by said side walls. The ramp member extends outwardlyfrom the base 12 while said side walls 11 are withdrawn from the base(FIG. 2) and facilitates unloading of any contained product.

[0012] Preferably, and as shown, the packaging configuration includes aplurality of ramp members, here shown as two members 14 a and 14 b. Eachof the ramp members is formed by a structural member 16 a, 16 b, whichpreferably is formed of plywood sheet or similar material such asoriented strand board (OSB), reinforced plastic sheeting, or the like.The structural members 16 a, 16 b define a product supporting surface,the upper surface as shown, for bearing the weight of the productcontained within the packaging. In a two ramp configuration, the rampsare spaced apart and arrayed parallel on to the other, as will beintuitively understood. More than two members may be provided whereappropriate to the product contained, as where necessary to support alarge weight or a multiplicity of casters as described more fullyhereinafter.

[0013] The structural members 16 a, 16 b are engaged by correspondingcushioning members 18 a, 18 b here also described as caster guides. Inthe illustrated embodiment, the caster guides are made out of foam andserve several purposes. First, the members 18 a, 18 b guide casterspresent on a packaged product and keep them on the ramp as the productis moved down the ramp during unloading (FIG. 2). Second, they supportthe outboard hinged portion of the structural member during use, whichallows the use of thinner and less material per ramp, reducing costs.Third, they provide protection against bumps and shock reaching theproduct on the side where the ramps are located during shipment (FIG.1).

[0014] The present invention contemplates that the base 12 of theapparatus 10 may be received for shipment on a pallet of conventionalconstruction. The base 12 preferably has a tray and at least one bottomcushion. Two bottom cushions 20 a, 20 b are shown. The bottom cushions,similarly to the caster guides, are made out of foam and serve severalpurposes. First, the cushions 20 a, 20 b receive and support a packagedproduct. Second, they support the inboard hinged portion of thestructural member during use, which allows the use of thinner and lessmaterial per ramp, reducing costs. Third, they provide protectionagainst bumps and shock reaching the product from below during shipment.

[0015] Preferably and as shown, the structural member portion of theramp member is of elongate form and hinged in the middle. Approximatelyone half of the length of the structural member is located under thecontained product such that any casters provided rest on the structuralmember during shipment. This helps spread the weight of the product overthe bottom cushions without adding extra packaging materials. Thematerial on the opposite side of the hinge keeps the caster guide inplace during shipment and drops down into ramping position for ease ofuse when the top portion of the carton is removed.

[0016] Each caster guide performs two functions. First, it providesshock protection for the packaged product on the side it is placedagainst during shipment. Preferably, the guide is a standard cushioningmaterial (such as molded expanded polypropylene) and compresses when theproduct is dropped to reduce the G forces. The second function of thecaster guide is to contain and support the structural member or hingedramp. The hinged ramp preferably is made out of plywood and contains aplastic hinge. The combination of the cushioning material and structuralmember allows for a more cost effective and simplistic package systemfor castered products.

[0017] As will be understood form the discussion above, the packagingsystem of this invention has each element of the package designed toperform several functions. The structural member 16 a, 16 b is designedto fit inside a cavity in the bottom cushion 20 a, 20 b. A protrusionsuch as a wood block is preferably provided on the bottom side of thestructural member to fit into an open cavity in the bottom of the bottomcushion and keep the structural member in position when loading andunloading the castered product. In unloading, the castered product isrolled down the ramps provided.

[0018] In the drawings and specifications there has been set forth apreferred embodiment of the invention and, although specific terms areused, the description thus given uses terminology in a generic anddescriptive sense only and not for purposes of limitation.

What is claimed is:
 1. Apparatus comprising: a container having at leastfour side walls and a base encircled by said side walls; and at leastone product unloading ramp member having a portion hingedly connected tosaid base and extending therefrom to lie alongside one of said sidewalls while said base is encircled by said side walls; said ramp memberextending outwardly from said base while said side walls are withdrawnfrom said base and facilitating unloading from said apparatus of anycontained product.
 2. Apparatus according to claim 1 comprising a pairof said ramp members spaced one from the other and extending parallelone to the other.
 3. Apparatus according to claim 3 wherein each of saidramp members comprises a structural member defining a product contactingsurface and a cushioning member disposed adjacent said structural memberand positioned to contact a floor surface when said ramp member isextended outwardly from said base.
 4. Apparatus according to claim 3wherein each said cushioning member has guide portions partiallyenclosing the adjacent one of said structural members and defining withsaid structural member a guiding channel which further facilitatesunloading from said apparatus of any contained product.
 5. Apparatusaccording to claim 1 wherein said ramp member comprises a structuralmember defining a product contacting surface and a cushioning memberdisposed adjacent said structural member and positioned to contact afloor surface when said ramp member is extended outwardly from saidbase.
 6. Apparatus according to claim 5 wherein said cushioning memberhas guide portions partially enclosing said structural member anddefining with said structural member a guiding channel which furtherfacilitates unloading from said apparatus of any contained product. 7.Apparatus comprising: a bottom tray; a bottom cushion disposed in saidbottom tray and cushioning any product received thereon; an externalcarton having at least four side walls and disposed to encircle saidbottom tray; an elongate structural member having a first portiondisposed on said bottom cushion and a second portion extending therefromto lie alongside one of said side walls; and a side cushion disposedadjacent said second portion of said structural member and cushioningany product disposed within said side walls; said structural member andsaid side cushion together defining a ramp member and being positionedto contact a floor surface when said carton is removed from said trayand said ramp member is extended outwardly from said tray to facilitateunloading from said apparatus of any contained product.
 8. Apparatusaccording to claim 7 comprising a plurality of pairs of said structuralmember and said side cushion, said pairs being spaced one from anotherand extending parallel one to another.
 9. Apparatus according to claim 8wherein each said side cushion has guide portions partially enclosingthe cooperating one of said structural members and defining as a portionof said ramp member a guiding channel which further facilitatesunloading from said apparatus of any contained product.
 10. Apparatusaccording to claim 7 wherein said side cushion has guide portionspartially enclosing said structural member and defining with saidstructural member a guiding channel which further facilitates unloadingfrom said apparatus of any contained product.
 11. Apparatus comprising:a bottom tray; a bottom cushion disposed in said bottom tray andcushioning any product supported thereon; an external carton having atleast four side walls and disposed to encircle said bottom tray; anelongate structural member having a first portion disposed on saidbottom cushion and a second portion extending therefrom to lie alongsideone of said side walls; a shipped product resting on said first portionof said structural member and disposed within said external carton; anda side cushion disposed adjacent said second portion of said structuralmember and cushioning said product; said structural member and said sidecushion together defining a ramp member and being positioned to contacta floor surface when said carton is removed from said tray and said rampmember is extended outwardly from said tray to facilitate unloading fromsaid apparatus of said product.
 12. Apparatus according to claim 11comprising a plurality of pairs of said structural member and said sidecushion, said pairs being spaced one from another and extending parallelone to another.
 13. Apparatus according to claim 12 wherein each saidside cushion has guide portions partially enclosing the cooperating oneof said structural members and defining as a portion of said ramp membera guiding channel which further facilitates unloading of said product.14. Apparatus according to claim 11 wherein said side cushion has guideportions partially enclosing said structural member and defining withsaid structural member a guiding channel which further facilitatesunloading of said product.
 15. Apparatus according to claim 11 furthercomprising casters mounted on said product and engaging said structuralmember to facilitate rolling said product from a position on said tray.